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Welding a Jig 


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Welding a Jig 

Written By: Mister Jalopy 


C-clamp (2) 


A joint that is not clean and tight will end up having an ugly, weak weld. Let's make a jig, an 
invaluable tool that holds two chunks of metal at right angles while allowing ample room to 
weld tacks in the corner. 

© Make Projects 

Page 1 of 4 

Welding a Jig 

• Lay out the angle iron on the inside 
of the square and measure 1" from 
the inside corner. Clamp the cross 
bar behind it at about the 3" point. 

Don't use your 

granddaddy's favorite • 

square. Anything could happen! 


• When welded, the diagonal 
cross bar will hold the angle 
iron at 90 degrees until California 
falls in the ocean. 

• Make sure the clamps are right and flip it over. Weld tacks at points 1 , 2, 3, and 4. Tack 
weld a nice, hot tack at each of the points. 

• Try G-4 for about 1 second at each point. The tack welds don't have to be gigantic, 
since they are just holding it together so you can remove the clamps and weld a 
bead. Re-trim the wire stick-out to 3/8" after each weld. 

© Make Projects 

Page 2 of 4 

Welding a Jig 

• A pair of not great-looking tacks, 
but it will hold. The left tack is 
particularly puny and I should have 
continued welding for another half 

• As with the sample beads, start on 
the left and drag across to the 

• With a 3/8" stick-out, touch the 
wire joint between the angle and 
flat bar, pull the trigger, and keep at 
a 45° angle. 

• Like laying a bead of caulk, 
just fill the joint with metal! 

• Before tacking the clamp, make 
sure to remove any paint from the 
clamp edges that will be welded. 
Then, tack it like you tacked the 
angle iron. Repeat both sides, both 

© Make Projects 

Page 3 of 4 

Welding a Jig 

This project first appeared in MAKE Volume 03 . 

This document was last generated on 201 2-1 1 -02 06:33:31 AM. 

© Make Projects Page 4 of 4